Industrial Newsbriefs

October 2011

Welcome to this edition of Industrial Newsbriefs, produced by the Washington State University Extension Energy Program, and sponsored by the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE). Please forward this issue to those of your colleagues interested in industrial energy efficiency. View archive

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COMPRESSED AIR

Compressed air efficiency: beyond leak repair

"Are You Wasting Money Fixing Compressed Air Leaks" was written by Ron Marshall and Bill Scales for the Compressed Air Challenge, and appears in the September 2011 issue of Maintenance Technology. The article explains inaccuracies common to the calculation of savings from compressed air leak repairs, and suggests changes to compressor controls to maximize efficiency and reduce costs.

ENERGY MANAGEMENT

Cement plant energy savings

"Reduce Energy Consumption: Cement Production," written by Patrick Murray of Rockwell Automation and published in the September 2011 issue of Control Engineering, provides an overview of the steps necessary to reduce manufacturing plant energy consumption, using cement plants as a study subject. The basics of energy assessment, monitoring, load profile, power quality monitoring, and cost allocation are summarized, and a typical audit scope and timeline are presented.

Incorporating ISO 14001 into a sustainability management plan

A three-part series of articles from Sustainable Plant, "How Sustainability Dovetails with ISO 14001," outlines how manufacturing facilities can incorporate the international environmental management standard ISO 14001 into a comprehensive facility-wide sustainability management system. Part I, Energy and Waste, focuses on energy savings and solid waste recycling. Part II, Safety, covers plant safety management and preventative maintenance. Part III, Clean and Profitable, discusses how to set, meet, and keep track of clean energy and sustainability measures across the supply chain.

HEAT RECOVERY

Heat recovery from gas compression

When gas is compressed, some of the energy is inevitably converted into heat rather than pressure. "Recover Heat from Compressors," written by Ben Sliwinski and published September 20, 2011, in Sustainable Plant, discusses methods for recovering much of this heat for space and water heating inside the plant. The author shows that heat recovery from compressors can save energy and make financial sense, especially when planning begins early so that expensive retrofits can be avoided.

HVAC/R (Heating, Ventilation, Air Conditioning, and Refrigeration)

Chilled water system efficiency

"7 Steps to Optimizing a Central Plant" was written by Dave Klee, LEED AP, Johnson Controls; it was published in the August 2011 issue of HPAC Heating/Piping/AirConditioning Engineering. It shows that modern chilled-water plants lose efficiencies because they are not maintained as a unit, but as a series of separate components. The author presents seven steps which treat the entire chilled-water plant as a unified system. Each of the seven is described in useful detail.

Fan belt tension optimization

"Ensuring Proper Fan-Belt Tension," by Brian Mleziva, Greenheck Fan Corp., was published in the July 2011 issue of HPAC Heating/Piping/AirConditioning Engineering. It shows how to measure fan-belt tension so the tension is appropriate for the application, thus ensuring performance and long-life for both the fan and its motor. The focus of the article is on V-belts. The article includes a table showing recommended minimums for belt-deflections, another table showing recommended belt-tensioning slots and several illustrations.

PUMPS

Tips for efficient pump operation

Opportunities for increasing the energy efficiency of pump systems are discussed in "Don’t Overwork Pumps and Fans: Part 1," written by V. Venkatesan and published September 23, 2011, in Sustainable Plant. The article outlines steps for optimizing the energy efficiency of pump systems, including methods for switching to variable speed operation, identifying and eliminating double pumping, and others.

SOLAR ENERGY

Solar energy for metalworking

A pilot project being conducted at a German metal processing plant is using solar parabolic panels to create saturated steam. The pilot was designed to investigate the applications of solar parabolic steam for industrial uses, and so far the results have been encouraging. "Solar-Powered Metalworking," published September 13, 2011 at CleanTechnica.com, provides an overview. Further details can be found in "The Sunny Side of Saturated Steam" (published in German in 2011 by BINE Information Services).

Oregon winery powered by solar

Powers Winery/Badger Mountain Vinyard in Kennewick, Washington, recently installed a 2200 sq. ft. solar array to help power its winemaking and bottling operations. The array is expected to provide 18% of the winery’s energy needs, and should pay for itself in about four years. For details, see "Powers Winery, Vinyard Embraces the Sun," published September 3, 2011, in the Bellingham Herald.

NEWS

Training dollars for energy efficient manufacturing

On September 13, 2011, The U.S. Department of Energy (DOE) announced over $30 million in funding for the training of undergraduate and graduate level engineering students to conduct energy assessments in manufacturing facilities. As part of the training process, each university will complete about 20 energy assessments per year in local manufacturing plants. To learn more, read the DOE press release.

ITP State Activities website updated

The DOE Industrial Technologies Program (ITP) released an update to the State Activities website in September 2011. The site contains a plethora of statistics about industry, industrial energy use, and economic indicators for each state, and now includes an interactive map with details about state ITP activities, a comprehensive list of partner projects, and local contact information for industrial energy efficiency assistance.

UPCOMING EVENTS AND TRAININGS

Pacific Northwest

Energy Efficiency of Chilled Water Systems and Cooling TowersOctober 17, 2011Boise, IdahoChilled water systems, which provide cooling for industrial and commercial facilities, often account for a major portion of the energy consumed in these facilities. Attendees will learn how technology improvements can reduce energy costs by more than half. Topics include chiller machinery, refrigerant options, the impact of using variable speed for compressors, system pumps, and cooling towers. In addition, a case study will be presented that shows how an energy-efficient chiller was selected. This course will also address several cooling tower efficiency measures and other issues, including cooling tower sizing, approach control strategies (efficient fan operation), water treatment (including ozone), and water conservation. This course includes a case study exercise that works through an example of how a cost-effective and efficient cooling tower was selected.

Adjustable Speed Drive Applications and Energy EfficiencyOctober 18, 2011 (register by October 4)Tacoma, WashingtonThis course addresses the choices available and relevant issues regarding the use of adjustable speed drives (ASD) with electric motors, and demonstrates the energy cost savings and other benefits made possible by this technology. In this course we explore how adjustable speed drives work and ways to assess the savings. Variable frequency drives (VFD) are the most common speed control method and is the major focus of the course content which will cover the benefits of pulse width modulation technology as well as discovering and mitigating harmful electromagnetic interference that can cause motor failure.- Additional information on evaluating and specifying VFDs is provided.

Energy Data Analysis: Introduction to KPIsTwo Locations:October 20, 2011, Eugene OregonNovember 10, 2011, Helena, MontanaGain the basic tools that every company needs to manage energy as a controllable cost. Understand energy management as a systematic approach to monitor, control, and conserve energy, and learn how energy management is integral to reducing operating costs. You will leave this training with information that will help you effectively implement an energy management system at your company.

Adjustable Speed Drive Applications and Energy EfficiencyNovember 10, 2011 (Register by October 27)Hermiston, OregonRegistration Fee: $139This course addresses the choices available and relevant issues regarding the use of adjustable speed drives (ASD) with electric motors, and demonstrates the energy cost savings and other benefits made possible by this technology. In this course we explore how adjustable speed drives work and ways to assess the savings. Variable frequency drives (VFD) are the most common speed control method and is the major focus of the course content which will cover the benefits of pulse width modulation technology and well as discovering and mitigating harmful electromagnetic interference that can cause motor failure. Additional information on evaluating and specifying VFDs is provided.

Efficiency Connections NorthwestNovember 2 - 3, 2011 Tacoma, WashingtonEfficiency Connections Northwest-provides an opportunity for participants to tap into the collective knowledge of the efficiency community as national experts join regional innovators to share their success stories. Efficiency Connections Northwest-was developed by and for regional utility professionals at both public- and investor-owned utilities and is brought to you by NEEA.

Pumping System OptimizationNovember 9, 2011Idaho Falls, IdahoThe typical medium-sized plant spends over $1.4 Million a year on energy to run their pumping systems. Better system design and optimized pumping systems may result in savings that will average $350K per year on energy alone. In addition, 4,436 tons of CO2 emissions may be avoided by implementing the systems optimization concepts discussed during this course. For irrigation users, the class can show how to lower header pressures without throttle valves and explore ways to modify pumps by trimming the impeller. The course will show how the variable speed drive can save additional power by slowing down the pump speed, which will save energy and reduce cost in the process. This training is coordinated by NEEA Industrial Training project and sponsored by Idaho Power Company, Idaho Office of Energy Resources, Bonneville Power Administration, Washington State University Energy Program, and Northwest Food Processors Association.

Energy Management: Introduction to Best PracticesNovember 30, 2011 Vancouver, WashingtonGain the basic tools that every company needs to manage energy as a controllable cost. Understand energy management as a systematic approach to monitor, control, and conserve energy, and learn how energy management is integral to reducing operating costs. You will leave this training with tools and resources that will help you effectively implement an energy management system at your company. This training includes practical exercises and in-class discussion.

Other Events, Trainings, and Webinars

Tuesday Webcast for Industry: Unveiling of the Implementation GuideOctober 11, 2011, 11:00 AM - 12:00 PM PSTThis webcast will provide a high-level overview of a new resource from the Industrial Technologies Program,-Guiding Principles for Successfully Implementing Industrial Energy Assessment Recommendations. This guidebook provides industry with guidance on how to successfully implement the recommendations identified during energy assessments. The webcast will address critical aspects of preparation and implementation before, during, and after an assessment and will focus on key strategies for ensuring not only implementation of recommendations but continuous energy efficiency improvement.

Understanding the Pros and Cons of Variable Frequency Drives(Webcast)October 25, 2011, 11:00 AM - 12:00 PM PSTIn the right applications, variable frequency drives (VFDs) offer great energy-savings potential from high power factor to improved speed control, soft-start capabilities, and more. This webinar will discuss how they work, the savings potential, best applications, sizing, and how to solve VFD power-quality issues.

PGE WEBINAR: Introduction to Compressed Air SystemsNovember 10, 2011, 12:00 PM PSTCompressed air systems can be one of the largest energy consumers in your facility. Learn how to start saving energy and money today. At this introduction webinar you will learn highlights from our four-hour seminar of how compressed air systems work and practical advice about making the most of your compressed air system investment. The four-hour seminar on this subject is scheduled December 1 in Wilsonville.

Advances in Lamps and Ballast (Webcast)November 17, 2011, 11:00 AM - 12:00 PM PSTA recent industry survey of over 100 lighting manufacturers identified the newest advances in fluorescent and metal halide lamps and ballasts. Attend this Webinar so that you can take advantage of the latest advances in lighting: extended T8/T5 lamp life, cold weather lamps, NEMA Premium ballasts, reduced wattage and high-temperature high bay fluorescents, radio frequency lighting, LEDs, and more! In addition, we will also tell you the latest about daylighting, occupancy sensors, and timers.

Steam End User Training - E-LearningSelf-paced online workshopThis course covers the operation of typical steam systems and discusses methods of system efficiency improvement. A brief demonstration of the BestPractices Steam System Tool Suite software is highlighted to help identify and quantify savings from selected potential improvement examples. The training is designed for plant personnel, such as energy managers, steam system supervisors, engineers, and equipment operators, who have steam system responsibilities in industrial and institutional plants.

Steam Systems E-LearningSelf-paced online workshopThis training course will provide an overview of the BestPractices Steam Tool Suite. The training course will begin with a navigational tutorial to guide you on how to move through the three modules. Each training module will demonstrate the capability of one tool and its interactions with the other tools. Interactive quizzes will be used to test your basic understanding of the tools after you complete the course.

MORE TRAININGS IN INDUSTRIAL ENERGY EFFICIENCY

For a listing of other upcoming industrial energy efficiency trainings, visit the following websites:

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If you have thoughts or ideas for what you would like to see in this publication, please email suggestions to Talia Mathews at MathewsT@energy.wsu.edu . We strive to keep this publication as useful and relevant as possible to you, our readers.